U.S. patent application number 11/867113 was filed with the patent office on 2008-04-10 for method of producing absorbent sheet with increased wet/dry cd tensile ratio.
This patent application is currently assigned to GEORGIA-PACIFIC CONSUMER PRODUCTS LP. Invention is credited to Steven L. Edwards, Bruce J. Kokko.
Application Number | 20080083519 11/867113 |
Document ID | / |
Family ID | 39274122 |
Filed Date | 2008-04-10 |
United States Patent
Application |
20080083519 |
Kind Code |
A1 |
Kokko; Bruce J. ; et
al. |
April 10, 2008 |
Method of Producing Absorbent Sheet with Increased Wet/Dry CD
Tensile Ratio
Abstract
A method of making absorbent cellulosic sheet with increased
wet/dry CD tensile ratio includes treating the fiber at high
consistency with debonder in a pulper, for example. The process
enables the use of large amounts of debonder in a wet-press process
in order to achieve wet/dry CD tensile ratios of greater than
30%.
Inventors: |
Kokko; Bruce J.; (Neenah,
WI) ; Edwards; Steven L.; (Fremont, WI) |
Correspondence
Address: |
PATENT GROUP GA030-43;GEORGIA-PACIFIC LLC
133 PEACHTREE STREET, N.E.
ATLANTA
GA
30303-1847
US
|
Assignee: |
GEORGIA-PACIFIC CONSUMER PRODUCTS
LP
Atlanta
GA
|
Family ID: |
39274122 |
Appl. No.: |
11/867113 |
Filed: |
October 4, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60850681 |
Oct 10, 2006 |
|
|
|
Current U.S.
Class: |
162/9 ; 162/111;
162/118; 162/158 |
Current CPC
Class: |
D21H 21/18 20130101;
D21H 21/20 20130101; D21F 11/14 20130101; D21H 25/005 20130101 |
Class at
Publication: |
162/9 ; 162/111;
162/118; 162/158 |
International
Class: |
B31F 1/12 20060101
B31F001/12; B28B 21/48 20060101 B28B021/48; D21C 9/00 20060101
D21C009/00; D21H 23/00 20060101 D21H023/00 |
Claims
1. A method of making absorbent cellulosic sheet with increased
wet/dry CD tensile ratio comprising: a) preparing an aqueous
furnish consisting essentially of cellulosic papermaking fibers in
aqueous suspension having a consistency of greater than 2 percent;
b) treating the aqueous furnish at greater than 2 percent
consistency with from about 5 lbs of debonder per ton of
papermaking fiber to about 30 lbs of debonder per ton of
papermaking fiber; c) adding a permanent wet strength resin to the
aqueous furnish in an amount of from about 5 lbs of permanent wet
strength per ton of papermaking fiber to about 50 lbs of permanent
wet strength resin per ton of papermaking fiber, the step of adding
a permanent wet strength agent to the aqueous furnish being carried
out subsequent to the step of treating the aqueous furnish with
debonder; d) diluting the aqueous furnish to a consistency of less
than the consistency at which the furnish was treated with
debonder; e) depositing the diluted aqueous furnish onto a
foraminous support traveling in a machine direction at a wire speed
by way of a jet of the diluted aqueous furnish having a jet
velocity in the machine direction; f) dewatering the furnish on the
foraminous support to form a nascent web; g) wet-pressing the
nascent web onto a rotating cylinder; and h) drying the web to
produce the cellulosic sheet; wherein the steps of dewatering,
wet-pressing and drying the web as well as the jet to wire velocity
delta are controlled and the furnish, debonder, and permanent wet
strength resin are selected and utilized in amounts such that the
absorbent cellulosic sheet has a wet/dry CD tensile ratio of
greater than 30 percent.
2. The method according to claim 1, wherein the papermaking fiber
includes Kraft softwood fiber in an amount of at least 25 percent
by weight of fiber.
3. The method according to claim 2, wherein the steps of
dewatering, wet-pressing and drying the web as well as the jet to
wire velocity delta are controlled and the furnish, debonder, and
permanent wet strength resin are selected and utilized in amounts
such that the absorbent cellulosic sheet has a wet/dry CD tensile
ratio of greater than 30 percent and an MD/CD dry tensile ratio of
less than 1.5.
4. The method according to claim 2, wherein the steps of
dewatering, wet-pressing and drying the web as well as the jet to
wire velocity delta are controlled and the furnish, debonder, and
permanent wet strength resin are selected and utilized in amounts
such that the absorbent cellulosic sheet has a wet/dry CD tensile
ratio of greater than 30 percent and an MD/CD dry tensile ratio of
less than 1.
5. The method according to claim 2, wherein the aqueous furnish is
treated with debonder at a consistency between about 3 and about 8
percent.
6. The method according to claim 2, wherein further comprising
adding a dry strength resin to the furnish prior to diluting the
furnish.
7. A method of making absorbent cellulosic sheet with increased
wet/dry CD tensile ratio comprising: a) preparing an aqueous
furnish consisting essentially of cellulosic papermaking fibers in
aqueous suspension having a consistency of greater than 2 percent;
b) treating the aqueous furnish at greater than 2 percent
consistency with from about 5 lbs of debonder per ton of
papermaking fiber to about 30 lbs of debonder per ton of
papermaking fiber; c) subsequent to the step of treating the
aqueous furnish at greater than 2 percent consistency with
debonder, adding a permanent wet strength resin to the aqueous
furnish in an amount of from about 5 lbs of permanent wet strength
per ton of papermaking fiber to about 50 lbs of permanent wet
strength resin per ton of papermaking fiber; d) diluting the
aqueous furnish to a consistency of less than the consistency at
which the furnish was treated with debonder; e) depositing the
diluted aqueous furnish onto a foraminous support traveling in a
machine direction at a wire speed by way of a jet of the diluted
aqueous furnish having a jet velocity in the machine direction; f)
compactively dewatering the furnish to form a nascent web having an
apparently random distribution of papermaking fiber; g) applying
the dewatered web having the apparently random fiber distribution
to a translating transfer surface moving at first speed; h)
belt-creping the web from the transfer surface at a consistency of
from about 30 percent to about 60 percent utilizing a patterned
creping belt, the creping step occurring under pressure in a belt
creping nip defined between the transfer surface and the creping
belt wherein the belt is traveling at a second speed slower than
the speed of said transfer surface, the belt pattern, nip
parameters, velocity delta and web consistency being selected such
that the web is creped from the transfer surface and redistributed
on the creping belt to form a web with a reticulum having a
plurality of interconnected regions of different local basis
weights including at least (I) a plurality of fiber-enriched
pileated regions of high local basis weight, as well as (II) a
plurality of regions of compressed papermaking fibers, the
compressed regions having relatively low local basis weight; and i)
drying the web to produce the cellulosic sheet; wherein the steps
of dewatering and applying the web to the transfer surface, belt
creping, wet-pressing, and drying the web as well as the jet to
wire velocity delta are controlled and the furnish, debonder, and
permanent wet strength resin are selected and utilized in amounts
such that the absorbent cellulosic sheet has a wet/dry CD tensile
ratio of greater than 30 percent.
8. The method according to claim 7, wherein the papermaking fiber
includes Kraft softwood fiber in an amount of at least 25 percent
by weight of fiber.
9. The method according to claim 8, wherein the steps of
dewatering, wet-pressing and drying the web as well as the jet to
wire velocity delta are controlled and the furnish, debonder, and
permanent wet strength resin are selected and utilized in amounts
such that the absorbent cellulosic sheet has a wet/dry CD tensile
ratio of greater than 30 percent and an MD/CD dry tensile ratio of
less than 1.5.
10. The method according to claim 8, wherein the steps of
dewatering, wet-pressing and drying the web as well as the jet to
wire velocity delta are controlled and the furnish, debonder, and
permanent wet strength resin are selected and utilized in amounts
such that the absorbent cellulosic sheet has a wet/dry CD tensile
ratio of greater than 30 percent and an MD/CD dry tensile ratio of
less than 1.
11. The method according to claim 8, wherein the aqueous furnish is
treated with debonder at a consistency between about 3 and about 8
percent.
12. The method according to claim 8, wherein the step of adding a
dry strength resin to the furnish is carried out prior to diluting
the furnish.
13. A method of making absorbent cellulosic sheet with increased
wet/dry CD tensile ratio comprising: a) preparing an aqueous
furnish consisting essentially of cellulosic papermaking fibers in
aqueous suspension having a consistency of greater than 2 percent,
the papermaking fiber including at least about 40 percent by weight
Kraft softwood fiber; b) treating the aqueous furnish at greater
than 2 percent consistency with from about 5 lbs of debonder per
ton of papermaking fiber to about 30 lbs of debonder per ton of
papermaking fiber; c) subsequent to the step of treating the
aqueous furnish at greater than 2 percent consistency with
debonder, adding a permanent wet strength resin to the aqueous
furnish in an amount of from about 5 lbs of permanent wet strength
per ton of papermaking fiber to about 50 lbs of permanent wet
strength resin per ton of papermaking fiber; d) thereafter diluting
the aqueous furnish to a consistency of less than the consistency
at which the furnish was treated with debonder and less than the
consistency at which permanent wet strength resin was added; e)
depositing the diluted aqueous furnish onto a foraminous support
traveling in a machine direction at a wire speed by way of a jet of
the diluted aqueous furnish having a jet velocity in the machine
direction; f) dewatering the furnish to form a web; and g) drying
the web to produce the cellulosic sheet; wherein the steps of
dewatering and drying the web are controlled and the furnish,
debonder, and permanent wet strength resin are selected and
utilized in amounts such that the absorbent cellulosic sheet has a
wet/dry CD tensile ratio of greater than 30 percent.
14. The method according to claim 13, wherein the step of preparing
the aqueous furnish comprises pulping the fiber in a pulping vessel
and wherein the furnish is treated with debonder in the pulping
vessel.
15. The method according to claim 13, further comprising the step
of refining at least a portion of the papermaking fiber.
16. The method according to claim 13, further comprising the step
of blending the debonder-treated aqueous furnish with another
aqueous furnish containing papermaking fiber.
17. The method according to claim 16, wherein at least 50 percent
by weight of the papermaking fiber in the sheet is pretreated with
debonder.
18. The method according to claim 16, wherein at least 75 percent
by weight of the papermaking fiber in the sheet is pretreated with
debonder.
19. The method according to claim 16, wherein at least 90 percent
by weight of the papermaking fiber in the sheet is pretreated with
debonder.
20. The method according to claim 13, wherein the papermaking
furnish also comprises recycle fiber.
21. In a method of making absorbent sheet comprising feeding
papermaking fiber to a pulper and pulping the fiber at a
consistency of greater than 2 percent and subsequently supplying
the pulped fiber to a machine chest where the fiber is fed forward
for dilution and feeding to a headbox, the improvement comprising
treating Kraft softwood fiber with debonder at a consistency of
greater than 2 percent prior to supplying the pulped Kraft softwood
fiber to the machine chest.
22. The improvement according to claim 21, wherein substantially
all of the Kraft softwood fiber in the sheet is treated with
debonder at a consistency of greater than 3 percent.
23. The method according to claim 21, wherein the step of preparing
the aqueous furnish comprises pulping the fiber in a pulping vessel
and wherein the furnish is treated with debonder in the pulping
vessel.
24. The method according to claim 21, further comprising the step
of blending the debonder-treated aqueous furnish with another
aqueous furnish containing papermaking fiber, and wherein at least
50 percent by weight of the papermaking fiber in the sheet is
pretreated with debonder.
25. An absorbent cellulosic sheet consisting essentially of
cellulosic papermaking fiber having an MD/CD dry tensile ratio of
less than 1 and a wet/dry CD tensile ratio of greater than 30
percent.
Description
CLAIM FOR PRIORITY
[0001] This non-provisional patent application is based upon U.S.
Provisional Patent Application Ser. No. 60/850,681, of the same
title, filed Oct. 10, 2006, the priority of which is hereby claimed
and the disclosure of which is hereby incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present invention relates to absorbent sheet of the
class used to make paper towel. In particular, the present
invention relates to a method of making such products with high
relative CD wet tensile including, in one embodiment, treating
softwood Kraft papermaking fiber with a debonder at consistencies
of greater than 2 percent and subsequently adding a wet strength
resin. Especially preferred products have wet/dry CD tensile ratios
of greater than 30 percent, as well as MD/CD dry tensile ratios of
less than 1.
BACKGROUND
[0003] The dry strength of a paper towel or tissue is often
dictated by the required wet strength of the product in-use. In
particular, the MD dry tensile may be higher than needed in order
to provide sufficient CD wet strength which, as one of skill in the
art will appreciate adversely affects softness of the towel. One
approach to ameliorating the softness/wet strength conflict is
through the use of wet strength resins, in combinations, for
example, such as a cationic wet strength resin and a
hydrophobically modified anionic polyelectrolyte. See U.S. Pat. No.
7,041,197 to Kokko et al.
[0004] The CD wet/dry ratio tensile is a convenient parameter by
which to characterize absorbent paper products, it being noted that
higher wet/dry CD tensile ratios are desirable, for example, in
order to provide for softer paper toweling. It has been disclosed
in U.S. Pat. No. 6,461,476 to Goulet et al. that the wet/dry
tensile of throughdried tissue and towels can be increased by
treating the pulp with a debonder, a wet strength agent and a dry
strength agent.
[0005] Chemical debonders, also referred to as softeners, are
frequently employed in the manufacture of paper tissue and towel.
One preferred debonder composition includes a softener system
comprising an ion-paired mixture of an anionic surfactant and a
cationic quaternary ammonium compound. Details are seen in U.S.
Pat. No. 6,245,197 to Oriaran et al. Typically, debonders are added
to the papermaking furnish at relatively low fiber consistencies,
such as are seen in a stock chest or a machine chest. In this
regard, see U.S. Pat. No. 5,785,813 to Smith et al.; note FIG. 1
thereof wherein hardwood fiber is treated with debonder. Note also,
U.S. Pat. No. 5,501,768 to Hermans et al., Example 9, Col. 13
wherein kraft hardwood fiber is treated with debonder in a shaft
disperser.
[0006] The following patents also disclose papermaking processes
wherein a debonder composition is added after the fiber has been
pulped: U.S. Pat. No. 6,273,995 to Ikeda et al.; U.S. Pat. No.
6,146,494 to Seger et al.; and U.S. Pat. No. 4,441,962 to Osborn,
III.
[0007] It has been suggested to pre-treat high yield fiber with a
combination of oil and surfactant, prior to making absorbent sheet.
In this regard reference is made to U.S. Pat. No. 6,001,218 to Hsu
et al. and U.S. Pat. No. 6,074,527, also to Hsu et al. According to
the '218 and '527 patents, a pulp slurry is treated at elevated
temperature with oil and surfactant in order to produce softer
products.
[0008] It will be appreciated by one of skill in the art that the
prior art is replete with pulp treatments seeking to provide a
softer and/or stronger product. In this regard, the following
references are noted generally: United States Patent Publication
No. 2003/0024669 (U.S. Ser. No. 09/852,997) entitled "Use of
Hydrophobically Modified Polyaminamides With Polyethylene Glycol
Esters in Paper Products" of Kokko; United States Patent
Publication No. 2002/0162635 (U.S. Ser. No. 10/143,674) entitled
"Softer and Higher Strength Paper Products and Methods of Making
Such Products" of Hsu; United States Patent Publication No.
2002/0088575 (U.S. Ser. No. 09/942,468) entitled "Enzymatic
Treatment of Pulp to Increase Strength" of Lonsky et al.; United
States Patent Publication No. 2004/0123962 (U.S. Ser. No.
10/335,133) entitled "Amino-Functionalized Pulp Fibers" of Shannon
et al.; U.S. Pat. No. 6,582,560 entitled "Method for Using Water
Insoluble Chemical Additives with Pulp and Products Made By Said
Method" to Runge et al. See also United States Patent Publication
No. 2003/0159786 (U.S. Ser. No. 10/389,073) entitled "Method For
Using Water Insoluble Chemical Additives with Pulp and Products
Made by Said Method" of Runge et al.; United States Patent
Publication No. 2004/0045687 (U.S. Ser. No. 10/242,571) entitled
"Method for Using Water Insoluble Chemical Additives With Pulp and
Products Made by Said Method" of Shannon et al.; U.S. Pat. No.
6,344,109 entitled "Softened Comminution Pulp" to Gross; and United
States Patent Publication No. 2002/0074097 (U.S. Ser. No.
10/017,361) entitled "Softened Comminution Pulp", also to
Gross.
[0009] While numerous chemical packages are available for
increasing softness, wet strength and the like, additives are
expensive, can make processing difficult, foul equipment and so
forth. Indeed, in many cases, it is not possible to use high levels
of additives; for example, in wet-press processes, the amount of
debonder added by conventional means is limited to such amounts
that will not interfere substantially with adhesion of the web to a
rotating cylinder; typically no more than 4-5 lbs of debonder per
ton of fiber can be used.
SUMMARY OF INVENTION
[0010] It has been unexpectedly found that it is possible to add
high levels of debonder to wet-press processes and increase the
wet/dry CD tensile ratio in accordance with the invention. Debonder
is added to the furnish at relatively high consistency, upstream of
a machine chest, in a pulper for example, and prior to diluting the
furnish and pumping it to a headbox. Permanent wet strength resin
is preferably added to the furnish subsequent to the debonder
treatment. Overall properties are further enhanced by providing
base sheet with a relatively low MD/CD dry tensile ratio and
optionally providing a dry strength resin to the furnish.
[0011] Without intending to be bound by any theory, it is believed
that treating the furnish at relatively high consistency (greater
than 2 percent or greater than 3 percent) and prolonged contact
times leads to much better incorporation of the debonder into the
pulp, ameliorating processing issues such as adhesion difficulties
and unwanted deposits on fabrics and drying equipment.
[0012] Paper tensile strength, T, is described by the Page
equation,
1/T=9/(8Z)+12C/(PLbRBA)
[0013] For present purposes, we can ignore the parameters of
zero-span tensile (Z), fiber perimeter (P), fiber length (L), and
fiber coarseness (C) since they are the same in a given lot of
fiber. Beyond these fiber parameters, then, dry tensile is
primarily governed by the Relative Bonded Area (RBA) and wet
tensile by the shear bond strength term (b). As two fibers dry
together they collapse upon each other--driven into flat ribbons by
Campbell forces within the lumen and lamella. Any surfaces brought
into close enough contact to allow a hydrogen bond (H-bond) to form
will form H-bonds as the sheet dries. The combination of many
H-bonds, which is one of the weaker chemical bonds, can result in
considerable tensile strength. Dry tensile will further increase as
one adds other stronger bonds such as ionic and covalent bonds into
these contact regions, so that b increases, but the gain will be
small compared to the dry strength attributed to the plethora of
H-bonding. However, once the paper substrate is placed in water,
all these H-bonds are broken and only those bonds resistant to
water will remain to hold the structure together. The measured
tensile strength under these conditions is the wet tensile.
[0014] We believe that debonder functions to lower dry strength in
disproportion to wet tensile by reducing relative bonding while
minimally impacting shear bond strength; or in other words,
debonder affects fiber surface energy and not the microcomposite
responsible for the wet strength bond. Increasing debonder dosage
creates opportunity for improving wet/dry strength ratios; however,
relatively high dosage levels have not previously been practical as
noted above.
[0015] Large gains in wet/dry CD tensile ratios are observed with
debonder add-on rates of 10-20 lbs per ton of fiber is appreciated
from FIGS. 1 and 2.
[0016] FIG. 1 is a plot of wet breaking length versus dry breaking
length wherein it is seen that wet/dry CD tensile ratios were
increased 60 percent and more through the use of debonder treatment
at a pulper. The advantages of the invention are further seen in
FIG. 2, which is another plot of wet breaking length versus dry
breaking length for handsheets. It is seen in FIG. 2, for example,
that a refined towel substrate with a dry breaking length of 5 km
or so will have a wet breaking length of approximately 0.9 km.
Through the use of thick stock treatment with debonder in
accordance with the invention, the wet breaking length at the same
dry strength was increased to 1.4 km or 56 percent. The MD tensiles
necessary for a product of a predetermined CD wet strength can be
further reduced by controlling the MD/CD dry tensile ratio by way
of the jet/wire velocity delta and crepe as will be appreciated
from FIG. 3, which is a plot of MD/CD dry tensile ratio versus
jet/wire velocity delta. It is seen in FIG. 3 that the MD/CD
tensile ratios exhibit minima at delta values slightly less than
200 fpm and that a wet-crepe, fabric crepe process is less
sensitive to velocity delta changes and is more readily controlled
over a greater range than a conventional wet-press/dry crepe
process as further discussed herein. In other words, the relative
CD strength of the product may be greatly increased by controlling
the jet/wire velocity delta.
[0017] Further aspects and advantages of the present invention will
become readily apparent from the discussion which follows.
BRIEF DESCRIPTION OF DRAWINGS
[0018] The invention is described in detail below with reference to
the various drawings, wherein like numerals designate similar
ports. In the drawings:
[0019] FIG. 1 is a plot of wet CD tensile versus dry CD tensile for
various products showing wet/dry CD tensile ratios;
[0020] FIG. 2 is a plot of wet CD tensile versus CD dry tensiles
for handsheets made by adding a Type C quat to 1:1 unrefined
southern softwood Kraft (SSWK):southern hardwood Kraft (SHWK)
furnish, or 1:1 refined (590 CSF) SSWK:unrefined SHWK furnish at
the thick stock prior to addition of AMRES 25HP (PAE) alone, or
sequentially with AMRES 25HP and CMC;
[0021] FIG. 3 is a plot of MD/CD dry tensile ratio versus jet/wire
velocity delta for conventional wet-press (CWP) and wet-press,
fabric crepe (FC) processes;
[0022] FIG. 4 is a plot of wet CD tensile versus dry CD tensile for
handsheets made by adding a Type C quat to 1:1 unrefined SSWK:SHWK
furnish at the pulper (British disintegrator), or thick stock prior
to addition of AMRES 25HP and CMC;
[0023] FIG. 5 is a plot of wet CD tensile versus dry CD tensile for
handsheets made without debonder pre-treatment, specifically for
handsheets made with 1:1 unrefined SSWK:SHWK furnish, or 1:1
refined (590 CSF) SSWK:unrefined SHWK furnish, treated with either
AMRES 25HP (PAE) alone or sequentially with PAE and CMC in the
thick stock;
[0024] FIG. 6 is a flow diagram illustrating fiber pre-treatment
prior to feeding the furnish to a papermachine;
[0025] FIG. 7 is a schematic diagram of a conventional wet-press
(CWP) papermachine; and
[0026] FIG. 8 is a schematic diagram of a wet-press, wet crepe
fabric crepe (FC) papermachine.
DETAILED DESCRIPTION
[0027] The invention is described in detail below with reference to
several embodiments and numerous examples. Such discussion is for
purposes of illustration only. Modifications to particular examples
within the spirit and scope of the present invention, set forth in
the appended claims, will be readily apparent to one of skill in
the art.
[0028] Terminology used herein is given its ordinary meaning with
the exemplary definitions set forth immediately below. Test
specimens are conditioned for 2 hours at 50 percent relative
humidity and 23.degree. C..+-.1.degree. C. (73.4.degree.
F..+-.1.8.degree. F.) unless otherwise indicated.
[0029] Water Absorbency Rate or WAR is measured in accordance with
TAPPI method T-432 cm-99. Water absorbency rate is the time it
takes for a sample to absorb a 0.1 gram droplet of water disposed
on its surface by way of an automated syringe. The test specimens
are preferably conditioned at 23.degree. C..+-.1.degree. C.
(73.4.+-.1.8.degree. F.) at 50 percent relative humidity. For each
sample, 4 3.times.3 inch test specimens are prepared. Each specimen
is placed in a sample holder such that a high intensity lamp is
directed toward the specimen. 0.1 ml of water is deposited on the
specimen surface and a stop watch is started. When the water is
absorbed, as indicated by lack of further reflection of light from
the drop, the stopwatch is stopped and the time recorded to the
nearest 0.1 seconds. The procedure is repeated for each specimen
and the results averaged for the sample.
[0030] Throughout this specification and claims, when we refer to a
nascent web having an apparently random distribution of fiber
orientation (or use like terminology), we are referring to the
distribution of fiber orientation that results when known forming
techniques are used for depositing a furnish on the forming fabric.
When examined microscopically, the fibers give the appearance of
being randomly oriented even though, depending on the jet to wire
speed, there may be a significant bias toward machine direction
orientation, making the machine direction tensile strength of the
web exceed the cross-direction tensile strength.
[0031] Unless otherwise specified, "basis weight", BWT, bwt, and so
forth refers to the weight of a 3000 ft.sup.2 ream of product.
Consistency refers to percent solids of a nascent web, for example,
calculated on a bone dry basis. "Air dry" means including residual
moisture, by convention up to about 10 percent moisture for pulp
and up to about 6 percent for paper. A nascent web having 50
percent water and 50 percent bone dry pulp has a consistency of 50
percent.
[0032] "Base sheet" refers to a unitary cellulosic sheet as
manufactured by a papermachine. Base sheets may be layered;
however, they have a unitary structure not readily delaminated. A
"ply" of a finished product refers to base sheet incorporated into
the product.
[0033] The term "cellulosic", "cellulosic sheet" and the like is
meant to include any product incorporating fiber having cellulose
as a major constituent.
[0034] "Papermaking fibers" include virgin pulps or recycle
(secondary) cellulosic fibers or fiber mixes comprising cellulosic
fibers. Fibers suitable for making the webs of this invention
include: nonwood fibers, such as cotton fibers or cotton
derivatives, abaca, kenaf, sabai grass, flax, esparto grass, straw,
jute hemp, bagasse, milkweed floss fibers, and pineapple leaf
fibers; wood fibers such as those obtained from deciduous and
coniferous trees, including softwood fibers, such as northern and
southern softwood kraft fibers; and hardwood fibers, such as
eucalyptus, maple, birch, aspen, or the like. Papermaking fibers
can be liberated from their source material by any one of a number
of chemical pulping processes familiar to one experienced in the
art, including sulfate, sulfite, polysulfide, soda pulping, etc.
The pulp can be bleached if desired by chemical means including the
use of chlorine, chlorine dioxide, oxygen and so forth. The
products of the present invention may comprise a blend of
conventional fibers (whether derived from virgin pulp or recycle
sources) and high coarseness lignin-rich tubular fibers, such as
bleached chemical thermomechanical pulp (BCTMP). "Furnishes" and
like terminology refers to aqueous compositions including
papermaking fibers, wet strength resins, debonders, and the like
for making paper products. Synthetic fibers may also be included in
the furnish.
[0035] Kraft softwood fiber is low yield fiber made by the well
known Kraft (sulfate) pulping process from coniferous material and
includes northern and southern softwood Kraft fiber, Douglas fir
Kraft fiber and so forth. Kraft softwood fibers generally have a
lignin content of less than 5 percent by weight, a length weighted
average fiber length of greater than 2 mm, as well as an arithmetic
average fiber length of greater than 0.6 mm.
[0036] Kraft hardwood fiber is made by the Kraft process from
hardwood sources, i.e., eucalyptus and also has generally a lignin
content of less than 5 percent by weight. Kraft hardwood films are
shorter than softwood fibers, typically having a length weighted
average fiber length of less than 1 mm and an arithmetic average
length of less than 0.5 mm or less than 0.4 mm.
[0037] Fiber length can be measured by any suitable means. A
preferred system is the OpTest Fiber Quality Analyzer (FQA) from
OpTest Equipment, Hawkesbury, Ontario, Canada, Model No. Code LDA
96. The FQA measures individual fiber contour and projected lengths
by optically imaging fibers with a CCD camera and polarized
infrared light.
[0038] Recycle fiber which is predominantly low yield fiber may be
identified by lignin content. Recycle fiber having a lignin content
of less than 7.5 percent by weight is presumed to be predominantly
low yield fiber as opposed to groundwood.
[0039] As used herein, the "compactively dewatering the web or
furnish" refers to mechanical dewatering by wet-pressing on a
dewatering felt, for example, in some embodiments by use of
mechanical pressure applied continuously over the web surface, as
in a nip between a press roll and a press shoe wherein the web is
in contact with a papermaking felt. The terminology "compactively
dewatering" is used to distinguish processes wherein the initial
dewatering of the web is carried out largely by thermal means as is
the case, for example, in U.S. Pat. No. 4,529,480 to Trokhan and
U.S. Pat. No. 5,607,551 to Farrington et al. noted above.
Compactively dewatering a web thus refers, for example, to removing
water from a nascent web having a consistency of less than 30
percent or so by application of pressure thereto and/or increasing
the consistency of the web by about 15 percent or more by
application of pressure thereto. "Wet-press", "wet-pressing" and
like terminology refers to processes and machinery which include a
compactive dewatering step or related equipment. Typically, a wet
web is wet-pressed onto the surface of a rotating cylinder where
the consistency is lowered substantially in connection with
transfer, for example, where the web is transferred from a felt to
a Yankee cylinder in a CWP process or the web is transferred from a
felt to a transfer cylinder in a FC process. Both the CWP and FC
processes described herein are wet-press processes.
[0040] Softener or debonder add-on is calculated as the weight of
"as received" commercial debonder composition per ton of bone dry
fiber when using a commercially available debonder composition,
without regard to additional diluents or dispersants which may be
added to the composition after receipt from the vendor.
[0041] Debonder compositions are typically comprised of cationic or
anionic amphiphilic compounds, or mixtures thereof (hereafter
referred to as surfactants) combined with other diluents and
non-ionic amphiphilic compounds; where the typical content of
surfactant in the debonder composition ranges from about 10 wt % to
about 90 wt %. Diluents include propylene glycol, ethanol,
propanol, water, polyethylene glycols, and nonionic amphiphilic
compounds. Diluents are often added to the surfactant package to
render the latter more tractable (i.e., lower viscosity and melting
point). Some diluents are artifacts of the surfactant package
synthesis (e.g., propylene glycol). Non-ionic amphiphilic
compounds, in addition to controlling composition properties, can
be added to enhance the wettability of the debonder, where both
debonding and maintenance of absorbency properties are critical to
the substrate that a debonder is applied. The nonionic amphiphilic
compounds can be added to debonder compositions to disperse
inherent water immiscible surfactant packages in water streams,
such as encountered during papermaking. Alternatively, the nonionic
amphiphilic compound, or mixtures of different non-ionic
amphiphilic compounds, as indicated in U.S. Pat. No. 6,969,443 to
Kokko, can be carefully selected to predictably adjust the
debonding properties of the final debonder composition.
[0042] When formulating debonder composition directly from
surfactants, the debonder add-on includes amphiphilic additives
such as nonionic surfactant, i.e. fatty esters of polyethylene
glycols and diluents such as propylene glycol, respectively, up to
about 90 percent by weight of the debonder composition employed;
except, however that diluent content of more than about 30 percent
by weight of non-amphiphilic diluent is excluded for purposes of
calculating debonder composition add-on per ton of fiber. Likewise,
water content is excluded in calculating debonder add-on.
[0043] A "Type C" quat refers to an imidazolinium surfactant, while
a "Type C" debonder composition refers to a debonder composition
which includes Type C quat. A preferred Type C debonder composition
includes Type C quat, and anionic surfactant as disclosed in U.S.
Pat. No. 6,245,197 blended with nonionic amphiphilic components and
other diluents as is disclosed in U.S. Pat. No. 6,969,443. The
disclosures of the '197 and '443 patents are incorporated herein by
reference in their entireties.
[0044] "FC" means a fabric crepe process of the class discussed in
detail in connection with FIG. 5 or a product produced by that
technology as the context indicates. "TAD" on the other hand,
refers to products which are throughdried.
[0045] "Fpm" refers to feet per minute while "consistency" refers
to the weight percent fiber of the web.
[0046] "Freeness" or CSF is determined in accordance with TAPPI
Standard T 227 OM-94 (Canadian Standard Method).
[0047] Jet/wire velocity delta or like terminology refers to the
difference in speed between the headbox jet issuing from a headbox
and the forming wire or fabric speed in the MD; jet velocity-wire
velocity delta is typically expressed in fpm. In cases where a pair
of forming fabrics are used, the speed of the fabric advancing the
web in the machine direction is used to calculate jet/wire velocity
delta.
[0048] "MD" means machine direction and "CD" means cross-machine
direction.
[0049] Nip parameters include, without limitation, nip pressure,
nip width, backing roll hardness, fabric approach angle, fabric
takeaway angle, uniformity, nip penetration and velocity delta
between surfaces of the nip.
[0050] Nip width means the MD length over which the nip surfaces
are in contact.
[0051] "Predominantly" means more than 50 percent by weight of the
named species unless mole percent is specified. Papermaking fiber
from which a product is made is "predominantly" softwood fiber if
over 50 percent by weight of fiber in the product is softwood fiber
(bone dry).
[0052] A translating transfer surface refers to the surface from
which the web is creped into the creping fabric. The translating
transfer surface may be the surface of a rotating drum as described
hereafter, or may be the surface of a continuous smooth moving belt
or another moving fabric which may have surface texture and so
forth. The translating transfer surface needs to support the web
and facilitate the high solids creping as will be appreciated from
the discussion which follows.
[0053] Calipers and/or bulk reported herein may be 1, 4 or 8 sheet
calipers. The sheets are stacked and the caliper measurement taken
about the central portion of the stack. Preferably, the test
samples are conditioned in an atmosphere of
23.degree..+-.1.0.degree. C. (73.4.degree..+-.1.8.degree. F.) at 50
percent relative humidity for at least about 2 hours and then
measured with a Thwing-Albert Model 89-II-JR or Progage Electronic
Thickness Tester with 2-in (50.8-mm) diameter anvils, 539.+-.10
grams dead weight load, and 0.231 in./sec descent rate. For
finished product testing, each sheet of product to be tested must
have the same number of plies as the product is sold. For testing
in general, eight sheets are selected and stacked together. For
napkin testing, napkins are enfolded prior to stacking. For base
sheet testing off of winders, each sheet to be tested must have the
same number of plies as produced off the winder. For base sheet
testing off of the papermachine reel, single plies must be used.
Sheets are stacked together aligned in the MD. For handsheets,
single sheet caliper is used. On custom embossed or printed
product, try to avoid taking measurements in these areas if at all
possible. Bulk may also be expressed in units of volume/weight by
dividing caliper by basis weight.
[0054] Dry tensile strengths (MD and CD), stretch, ratios thereof,
break modulus, stress and strain are measured with a standard
Instron test device or other suitable elongation tensile tester
which may be configured in various ways, typically using 3 or 1
inch wide strips of tissue or towel, conditioned for 2 hours at 50
percent relative humidity and 23.degree. C..+-.1.degree. C.
(73.4.degree. F..+-.1.8.degree. F.), with the tensile test run at a
crosshead speed of 2 in/min. Tensile strength is typically reported
in breaking length (km) or g/3''.
[0055] Unless otherwise specified, a tensile property is a "dry"
property at break (i.e., peak value).
[0056] Tensile ratios are simply ratios of the values determined by
way of the foregoing methods. Dry tensile ratio refers to the MD/CD
dry tensile ratio unless otherwise stated. Tensile strength is
sometimes referred to simply as tensile.
[0057] Wet tensile is measured using a three-inch wide strip of
sheet that is folded into a loop, clamped in a special fixture
termed a Finch Cup, then immersed in water. The Finch Cup, which is
available from the Thwing-Albert Instrument Company of
Philadelphia, Pa., is mounted onto a tensile tester equipped with a
2.0 pound load cell with the flange of the Finch Cup clamped by the
tester's lower jaw and the ends of the specimen loop clamped into
the upper jaw of the tensile tester. The sample is immersed in
water that has been adjusted to a pH of 7.0.+-.0.1 and the tensile
is tested after a 5 second immersion time. The results are
expressed in breaking length(km) or g/3'', dividing by two to
account for the loop as appropriate.
[0058] Wet/dry tensile ratios are expressed in percent by
multiplying the wet/dry ratio by 100. For towel products, the
wet/dry CD tensile ratio is the most relevant. Throughout this
specification and claims which follow, "wet/dry ratio" or like
terminology refers to the wet/dry CD tensile ratio unless clearly
specified otherwise. For handsheets, MD and CD values are
equivalent.
[0059] "Belt Crepe Ratio" or "Fabric Crepe Ratio" is an expression
of the speed differential between a creping belt or creping fabric
and the forming wire, and typically calculated as the ratio of the
web speed immediately before creping and the web speed immediately
following creping, because the forming wire and transfer surface
are typically, but not necessarily, operated at the same speed:
Belt Crepe Ratio=transfer cylinder speed/creping belt speed
[0060] Belt Crepe can also be expressed as a percentage calculated
as:
Belt Crepe percent=(Belt Crepe Ratio-1).times.100 percent
[0061] Line crepe (sometimes referred to as overall crepe), reel
crepe and so forth are similarly calculated. A web creped from a
Yankee moving at a speed of 1000 fpm and wound onto a reel at 910
fpm has a reel crepe ratio of approximately 1.1 and a reel crepe of
approximately 10 percent.
[0062] PLI or pli means pounds force per linear inch.
[0063] Pusey and Jones (P+J) hardness (indentation), sometimes
referred to simply as P+J, is measured in accordance with ASTM D
531, and refers to the indentation number (standard specimen and
conditions).
[0064] Velocity delta means a difference in linear speed.
[0065] It has been found in accordance with the present invention
that elevated wet/dry CD tensile ratios are exhibited when the
papermaking fibers are pretreated with a debonder or softener
composition prior to their incorporation into the web. In this
respect, the present invention may employ debonders including amido
amine salts derived from partially acid neutralized amines. Such
materials are disclosed in U.S. Pat. No. 4,720,383. Evans,
Chemistry and Industry, 5 Jul. 1969, pp. 893-903; Egan, J. Am. Oil
Chemist's Soc., Vol. 55 (1978), pp. 118-121; and Trivedi et al., J.
Am. Oil Chemist's Soc., June 1981, pp. 754-756, incorporated by
reference in their entirety, indicate that softeners are often
available commercially only as complex mixtures rather than as
single compounds. While the following discussion will focus on the
predominant surfactant species, it should be understood that
commercially available mixtures and compositions would generally be
used in practice.
[0066] Quasoft 202-JR is a suitable material, which includes
surfactant derived by alkylating a condensation product of oleic
acid and diethylenetriamine. Synthesis conditions using a
deficiency of alkylation agent (e.g., diethyl sulfate) and only one
alkylating step, followed by pH adjustment to protonate the
non-ethylated species, result in a mixture consisting of cationic
ethylated and cationic non-ethylated species. A minor proportion
(e.g., about 10 percent) of the resulting amido amine cyclize to
imidazoline compounds. Since only the minor amounts of diethylquat
and imidazolinium portions of these materials are permanently
quaternary ammonium compounds, the compositions as a whole are
pH-sensitive. Therefore, in the practice of the present invention
with this class of chemicals, the pH in the head box should be
approximately 6 to 8, more preferably 6.5 to 8 and most preferably
7 to 8.
[0067] Quaternary ammonium compounds, such as dialkyl dimethyl
quaternary ammonium salts are also suitable particularly when the
alkyl groups contain from about 10 to 24 carbon atoms. These
compounds have the advantage of being relatively insensitive to
pH.
[0068] Biodegradable softeners can be utilized. Representative
biodegradable cationic softeners/debonders are disclosed in U.S.
Pat. Nos. 5,312,522; 5,415,737; 5,262,007; 5,264,082; and
5,223,096, all of which are incorporated herein by reference in
their entirety. The compounds are biodegradable diesters of
quaternary ammonia compounds, quaternized amine-esters, and
biodegradable vegetable oil based esters functional with quaternary
ammonium chloride and diester dierucyldimethyl ammonium chloride
and are representative biodegradable softeners.
[0069] Debonder compositions may include dialkyldimethyl-ammonium
salts of the formula:
##STR00001##
bis-dialkylamidoammonium salts of the formula:
##STR00002##
as well as dialkylmethylimidazolinium salts (Type C quats) of the
formula:
##STR00003##
wherein each R may be the same or different and each R indicates a
hydrocarbon chain having a chain length of from about twelve to
about twenty-two carbon atoms and may be saturated or unsaturated;
and wherein said compounds are associated with a suitable anion.
One suitable salt is a dialkyl-imidazolinium compound and the
associated anion is methylsulfate. Exemplary quaternary ammonium
surfactants include hexamethonium bromide, tetraethylammonium
bromide, lauryl trimethylammonium chloride, dihydrogenated tallow
dimethylammonium methyl sulfate, oleyl imidazolinium, and so
forth.
[0070] A nonionic surfactant component such as PEG diols and PEG
mono or diesters of fatty acids, and PEG mono or diethers of fatty
alcohols may be used as well, either alone or in combination with a
quaternary ammonium surfactant. Suitable compounds include the
reaction product of a fatty acid or fatty alcohol with ethylene
oxide, for example, a polyethylene glycol (PEG) diester or PEG
diether, respectively. Examples of nonionic surfactants that can be
used are polyethylene glycol dioleate, polyethylene glycol
dilaurate, polypropylene glycol dioleate, polypropylene glycol
dilaurate, polyethylene glycol monooleate, polyethylene glycol
monolaurate, polypropylene glycol monooleate and polypropylene
glycol monolaurate and so forth. Further details may be found in
U.S. Pat. No. 6,969,443 of Bruce Kokko (Attorney Docket 2130;
FJ-99-12), entitled "Method of Making Absorbent Sheet from Recycle
Furnish".
[0071] After debonder treatment, the pulp is mixed with strength
adjusting agents such as permanent wet strength resin (WSR),
optionally dry strength agents and so forth before the sheet is
formed. Suitable permanent wet strength agents are known to the
skilled artisan. A comprehensive but non-exhaustive list of useful
strength aids include urea-formaldehyde resins, melamine
formaldehyde resins, glyoxylated polyacrylamide resins,
polyamide-epichlorohydrin resins and the like. Thermosetting
polyacrylamides are produced by reacting acrylamide with diallyl
dimethyl ammonium chloride (DADMAC) to produce a cationic
polyacrylamide copolymer which is ultimately reacted with glyoxal
to produce a cationic cross-linking wet strength resin, glyoxylated
polyacrylamide. These materials are generally described in U.S.
Pat. No. 3,556,932 to Coscia et al. and U.S. Pat. No. 3,556,933 to
Williams et al., both of which are incorporated herein by reference
in their entirety. Resins of this type are commercially available
under the trade name of PAREZ. Different mole ratios of
acrylamide/-DADMAC/glyoxal can be used to produce cross-linking
resins, which are useful as wet strength agents. Furthermore, other
dialdehydes can be substituted for glyoxal to produce thermosetting
wet strength characteristics. Of particular utility are the
polyamide-epichlorohydrin permanent wet strength resins, an example
of which is sold under the trade names Kymene 557LX and Kymene 557H
by Hercules Incorporated of Wilmington, Del. and Amres.RTM. from
Georgia-Pacific Resins, Inc. These resins and the process for
making the resins are described in U.S. Pat. No. 3,700,623 and U.S.
Pat. No. 3,772,076 each of which is incorporated herein by
reference in its entirety. An extensive description of
polymeric-epihalohydrin resins is given in Chapter 2:
Alkaline-Curing Polymeric Amine-Epichlorohydrin by Espy in Wet
Strength Resins and Their Application (L. Chan, Editor, 1994),
herein incorporated by reference in its entirety. A reasonably
comprehensive list of wet strength resins is described by Westfelt
in Cellulose Chemistry and Technology Volume 13, p. 813, 1979,
which is incorporated herein by reference.
[0072] Suitable dry strength agents include starch, guar gum,
polyacrylamides, carboxymethyl cellulose (CMC) and the like. Of
particular utility is carboxymethyl cellulose, an example of which
is sold under the trade name Hercules CMC, by Hercules Incorporated
of Wilmington, Del.
[0073] An absorbent paper web is typically made commercially by
dispersing papermaking fibers and other papermaking components
noted above into an aqueous furnish (slurry) and depositing the
aqueous furnish onto the forming wire of a papermaking machine,
typically by way of a jet issuing from a headbox. Any suitable
forming scheme might be used. For example, an extensive but
non-exhaustive list in addition to Fourdrinier formers includes a
crescent former, a C-wrap twin wire former, an S-wrap twin wire
former, or a suction breast roll former. The forming fabric can be
any suitable foraminous member, including single layer fabrics,
double layer fabrics, triple layer fabrics, photopolymer fabrics,
and the like. Non-exhaustive background art in the forming fabric
area includes U.S. Pat. Nos. 4,157,276; 4,605,585; 4,161,195;
3,545,705; 3,549,742; 3,858,623; 4,041,989; 4,071,050; 4,112,982;
4,149,571; 4,182,381; 4,184,519; 4,314,589; 4,359,069; 4,376,455;
4,379,735; 4,453,573; 4,564,052; 4,592,395; 4,611,639; 4,640,741;
4,709,732; 4,759,391; 4,759,976; 4,942,077; 4,967,085; 4,998,568;
5,016,678; 5,054,525; 5,066,532; 5,098,519; 5,103,874; 5,114,777;
5,167,261; 5,199,261; 5,199,467; 5,211,815; 5,219,004; 5,245,025;
5,277,761; 5,328,565; and 5,379,808 all of which are incorporated
herein by reference in their entirety. One forming fabric
particularly useful with the present invention is Voith Fabrics
Forming Fabric 2164 made by Voith Fabrics Corporation, Shreveport,
La.
[0074] The nascent web may be dewatered on a papermaking felt. Any
suitable felt may be used. For example, felts can have double-layer
base weaves, triple-layer base weaves, or laminated base weaves.
Preferred felts are those having the laminated base weave design. A
wet-press-felt which may be particularly useful with the present
invention is Vector 3 made by Voith Fabric. Background art in the
press felt area includes U.S. Pat. Nos. 5,657,797; 5,368,696;
4,973,512; 5,023,132; 5,225,269; 5,182,164; 5,372,876; and
5,618,612. A differential pressing felt as is disclosed in U.S.
Pat. No. 4,533,437 to Curran et al. may likewise be utilized.
[0075] In wet-crepe, fabric crepe processes, referred to as FC
processes herein, suitable creping or textured fabrics include
single layer or multi-layer, or composite preferably open meshed
structures. Fabric construction per se is of less importance than
the topography of the creping surface in the creping nip as
discussed in more detail below. Long MD knuckles with slightly
lowered CD knuckles are greatly preferred for some products.
Fabrics may have at least one of the following characteristics: (1)
on the side of the creping fabric that is in contact with the wet
web (the "top" side), the number of machine direction (MD) strands
per inch (mesh) is from 10 to 200 and the number of cross-direction
(CD) strands per inch (count) is also from 10 to 200; (2) the
strand diameter is typically smaller than 0.050 inch; (3) on the
top side, the distance between the highest point of the MD knuckles
and the highest point on the CD knuckles is from about 0.001 to
about 0.02 or 0.03 inch; (4) in between these two levels there can
be knuckles formed either by MD or CD strands that give the
topography a three dimensional hill/valley appearance which is
imparted to the sheet; (5) the fabric may be oriented in any
suitable way so as to achieve the desired effect on processing and
on properties in the product; the long warp knuckles may be on the
top side to increase MD ridges in the product, or the long shute
knuckles may be on the top side if more CD ridges are desired to
influence creping characteristics as the web is transferred from
the transfer cylinder to the creping fabric; and (6) the fabric may
be made to show certain geometric patterns that are pleasing to the
eye, which is typically repeated between every two to 50 warp
yarns. One preferred fabric is a W013 Albany International
multilayer fabric. Such fabrics are formed from monofilament
polymeric fibers having diameters typically ranging from about 0.25
mm to about 1 mm. Such fabrics are formed from monofilament
polymeric fibers having diameters typically ranging from about 10
mm to about 100 mm. This fabric may be used to produce an absorbent
cellulosic sheet having variable local basis weight comprising a
papermaking fiber reticulum provided with (i) a plurality of
cross-machine direction (CD) extending, fiber-enriched pileated
regions of relatively high local basis weight interconnected by
(ii) a plurality of elongated densified regions of compressed
papermaking fibers, the elongated densified regions having
relatively low local basis weight and are generally oriented along
the machine direction (MD) of the sheet. The elongated densified
regions are further characterized by an MD/CD aspect ratio of at
least 1.5. Typically, the MD/CD aspect ratios of the densified
regions are greater than 2 or greater than 3; generally between
about 2 and 10. In most cases the fiber-enriched, pileated regions
have fiber orientation bias along the CD of the sheet and the
densified regions of relatively low basis weight extend in the
machine direction and also have fiber orientation bias along the CD
of the sheet. This product is further described in copending
application U.S. Provisional Patent Application Ser. No.
60/808,863, filed May 26, 2006, entitled "Fabric Creped Absorbent
Sheet with Variable Local Basis Weight" (Attorney Docket No. 20179;
GP-06-11), the disclosure of which is incorporated herein in its
entirety by reference.
[0076] The creping fabric may be of the class described in U.S.
Pat. No. 5,607,551 to Farrington et al., Cols. 7-8 thereof, as well
as the fabrics described in U.S. Pat. No. 4,239,065 to Trokhan and
U.S. Pat. No. 3,974,025 to Ayers. Such fabrics may have about 20 to
about 60 meshes per inch and are formed from monofilament polymeric
fibers having diameters typically ranging from about 0.008 to about
0.025 inches. Both warp and weft monofilaments may, but need not
necessarily be of the same diameter.
[0077] In some cases the filaments are so woven and complimentarily
serpentinely configured in at least the Z-direction (the thickness
of the fabric) to provide a first grouping or array of coplanar
top-surface-plane crossovers of both sets of filaments; and a
predetermined second grouping or array of sub-top-surface
crossovers. The arrays are interspersed so that portions of the
top-surface-plane crossovers define an array of wicker-basket-like
cavities in the top surface of the fabric, which cavities are
disposed in staggered relation in both the machine direction (MD)
and the cross-machine direction (CD), and so that each cavity spans
at least one sub-top-surface crossover. The cavities are discretely
perimetrically enclosed in the plan view by a picket-like-lineament
comprising portions of a plurality of the top-surface plane
crossovers. The loop of fabric may comprise heat set monofilaments
of thermoplastic material; the top surfaces of the coplanar
top-surface-plane crossovers may be monoplanar flat surfaces.
Specific embodiments of the invention include satin weaves as well
as hybrid weaves of three or greater sheds, and mesh counts of from
about 10.times.10 to about 120.times.120 filaments per inch
(4.times.4 to about 47.times.47 per centimeter). Although the
preferred range of mesh counts is from about 18 by 16 to about 55
by 48 filaments per inch (9.times.8 to about 22.times.19 per
centimeter).
[0078] Instead of an impression fabric, a dryer fabric may be used
as the creping fabric if so desired. Suitable fabrics are described
in U.S. Pat. No. 5,449,026 (woven style) and U.S. Pat. No.
5,690,149 (stacked MD tape yarn style) to Lee as well as U.S. Pat.
No. 4,490,925 to Smith (spiral style).
[0079] A creping adhesive used on a Yankee cylinder is preferably
capable of cooperating with the web at intermediate moisture to
facilitate transfer from the creping fabric to the Yankee and to
firmly secure the web to the Yankee cylinder as it is dried to a
consistency of 95 percent or more on the cylinder, preferably with
a high volume drying hood. The adhesive is critical to stable
system operation at high production rates and is preferably a
hygroscopic, re-wettable, substantially non-cross-linking adhesive
in the case of the Fabric Crepe process described herein. Examples
of preferred adhesives are those which include poly(vinyl alcohol)
of the general class described in U.S. Pat. No. 4,528,316 to
Soerens et al. Other suitable adhesives are disclosed in co-pending
U.S. Provisional Patent Application Ser. No. 60/372,255, filed Apr.
12, 2002, entitled "Improved Creping Adhesive Modifier and Process
for Producing Paper Products" (Attorney Docket No. 2394). The
disclosures of the '316 patent and the '255 application are
incorporated herein by reference. Suitable adhesives are optionally
provided with modifiers and so forth. It is preferred to use
cross-linker sparingly or not at all in the adhesive in many cases;
such that the resin is substantially non-crosslinkable in use.
EXAMPLES 1-7
Handsheet Preparation
[0080] British handsheets were prepared to a target basis weight of
around 60 g/m.sup.2 by treating either a 1:1 unrefined SSWK:SHWK
furnish or a 1:1 refined (590 CSF) SSWK:unrefined SHWK furnish
sequentially with a debonder, AMRES HP25 (PAE), and
carboxymethyl-cellulose (CMC), pressing at 15 psi/5 min, drying on
a heated drum dryer, and curing in a forced air oven at 105.degree.
C./5 min. For all preparations designated "pulper treatments" the
debonder was added to the furnish and disintegrated in a British
disintegrator for 30 min @ 3 percent consistency, then treated with
the PAE followed by CMC between 5 min intervals. The same procedure
was used for treatments designated thick stock treatments except
the debonder is added to the thick stock after the latter had been
disintegrated for 30 min. After adding the debonder the furnish was
stirred for 15 min prior to addition of PAE and CMC.
[0081] The debonders employed were Cartaflex.RTM. TNS available
from Clariant and an imidazolinium based debonder (referred to as
"Type C" debonder in Table 1 below). Generally, The Type C quat can
either be 1-(2-alkylamidoethyl)-2-alkyl-3-methylimidazolinium
methyl sulfate or halide or
1-(2-alkylamidoethyl)-2-alkyl-3-ethylimidazolinium ethylsulfate or
halide salts; where the content of the Type C quat in the debonder
composition ranges from about 10 wt % to about 90 wt % of the
debonder composition.
[0082] Details and results appear in FIG. 1 and in Table 1.
TABLE-US-00001 TABLE 1 Handsheet Data Wet End Chemicals Strength
Type Bulk Dry Wet WAR C, Cartaflex .RTM. WSR, CMC, B.W. Caliper,
Bulk, Tensile, B.L., Tensile, B.L., W/D 0.1 mL, Sample #/T TNS, #/T
#/T #/T lbs./rm g/m.sup.2 mils cm.sup.3/g g km g km Ratio sec. 1 0
0 20 4 39.4 64.1 6.3 2.5 8816 5.411 2399 1.473 27.2 21.0 2 0 5 20 4
39.9 64.9 6.8 2.7 6377 3.870 2154 1.307 33.8 15.4 3 0 10 20 4 40.8
66.4 6.9 2.6 5343 3.167 1848 1.095 34.6 13.2 4 0 20 20 4 40.2 65.5
6.9 2.7 3930 2.363 1472 0.885 37.5 12.4 5 5 0 20 4 40.3 65.6 6.4
2.5 7459 4.478 2519 1.512 33.8 16.3 6 10 0 20 4 40.3 65.6 6.6 2.6
5481 3.291 2151 1.291 39.2 14.9 7 20 0 20 4 41.6 67.7 6.9 2.6 3880
2.255 1694 0.985 43.7 16.0
[0083] It is seen in FIG. 1 that dramatic increases in wet/dry
ratios were achieved, particularly at debonder treatment levels of
10 lbs debonder/ton of fiber and more.
ADDITIONAL HANDSHEET EXAMPLES
[0084] Additional handsheet trials with Type C quat-based debonder
compositions showed that debonders performed equally well when
added during pulping at 3 percent or more consistency or when added
later to thick stock at 3 percent consistency, prior to the
addition of wet strength resin and dry strength resin. The
procedures employed were as noted in connection with Examples 1-7.
It is preferable to add the debonder before the strength additives.
While not to be bound by theory, it is believed that adding the
debonder before the strength additives maximizes debonder retention
in the substrate.
[0085] Results are seen in FIGS. 2 and 4, wherein "Type C" refers
to debonder treatment with Type C debonder, "R" means refined pulp;
"UR" refers to unrefined pulp, "T" refer to thick stock addition
and "P" refers to addition occurring during pulping. Results for
refined and unrefined fiber appear in FIG. 2, while results for
unrefined furnish appear in FIG. 4.
[0086] It is seen in FIG. 2 that treating the refined fibers with
debonder shifts the CD wet tensile to higher levels at a given wet
tensile; 50 percent higher CD wet tensiles and more at a given dry
tensile, allowing for large reduction in dry strength where wet
strength is the limiting property. It will be appreciated form FIG.
4 that, inasmuch as the debonder performs well at high levels when
added at the machine chest, it is better to add the debonder as far
"upstream" in the system as possible, preferably before the machine
chest in a commercial unit.
[0087] An unexpected relationship between debonder treatment and
refining is revealed by isolating the "control" data of FIG. 2,
that is, no debonder treatment, in FIG. 5. In FIG. 5, it is seen
that refining has a negative impact on wet/dry ratio; however, it
is seen in FIG. 2 that such negative impact is reversed by the
debonder treatment at high consistency. These unexpected results
provide better flexibility in meeting product specifications since
the wet and dry strength properties can be better managed through
refining without adverse impact in wet/dry ratio.
[0088] In a typical application of the present invention, debonder
is added to the furnish in a pulper 10 as shown in FIG. 6 which is
a flow diagram illustrating schematically pulp feed to a
papermachine. Debonder is added in pulper 10 while the fiber is at
a consistency of anywhere from about 4 percent to about 10 percent,
typically around 6 percent. Thereafter, the mixture is pulped after
debonder addition for 10 minutes or more before wet strength or dry
strength resin is added. The pulped fiber is fed forward to a
machine chest 12 and diluted, typically to a consistency of 3
percent or so. In machine chest 12 other additives, including
permanent wet strength resin and dry strength resin, may be added.
If so desired, the wet strength resin and dry strength resin may be
added in the pulper or upstream or downstream of the machine chest,
i.e., at 14 or 16; however, they should be added after debonder as
noted above and the dry strength resin is preferably added after
the wet strength resin. The furnish may be refined and/or cleaned
before or after it is provided to the machine chest as is known in
the art.
[0089] From machine chest 12, the furnish is further diluted to a
consistency of less than 2 percent, generally less than 1 percent
and typically 0.1 percent or so and fed forward to a headbox 20 by
way of a fan pump 18.
[0090] There is shown in FIG. 7 a schematic diagram of a
conventional wet-press (CWP) papermachine 15 with a divided headbox
thereby making it possible to produce a stratified product. The
product according to the present invention can be made with single
or multiple headboxes, 20, 20' and regardless of the number of
headboxes may be stratified or unstratified. The treated furnish is
transported through different conduits 40 and 41, where it is
delivered to the headbox of papermachine 15 as is well known,
although any convenient configuration can be used.
[0091] FIG. 7 shows a web-forming end or wet end with a liquid
permeable foraminous support member 11 which may be of any
convenient configuration. Foraminous support member 11 may be
constructed of any of several known materials including a
conventional papermaking felt, fabric or a synthetic filament woven
mesh base with a very fine synthetic fiber batt attached to the
mesh base. The foraminous support member 11 is supported in a
conventional manner on rolls, including breast roll 13, and
pressing roll, 17.
[0092] A forming fabric 24 is supported on rolls 19 and 21 which
are positioned relative to the breast roll 13 for guiding the
forming wire 24 to converge on the foraminous support member 11 at
the cylindrical breast roll 13 at an acute angle relative to the
foraminous support member 11. The foraminous support member 11 and
the wire 24 move at the same speed and in the same direction which
is the direction of rotation of the breast roll 13. The forming
wire 24 and the foraminous support member 11 converge at an upper
surface of the forming roll 13 to form a wedge-shaped space or nip
into which one or more jets of water or foamed liquid fiber
dispersion may be injected and trapped between the forming wire 24
and the foraminous support member 11 to force fluid through the
wire 24 into a save-all 22 where it is collected for re-use in the
process (recycled via line 25).
[0093] The nascent web W formed in the process is carried along the
machine direction 30 by the foraminous support member 11 to the
pressing roll 17 where the wet nascent web W is transferred to the
Yankee dryer 26. Fluid is pressed from the wet web W by pressing
roll 17 as the web is transferred to the Yankee dryer 26 where it
is dried and creped by means of a creping blade 27. The finished
web is collected on a take-up reel 28.
[0094] A pit 44 is provided for collecting water squeezed from the
furnish by the press roll 16, as well as collecting the water
removed from the fabric by a Uhle box 29. The water collected in
pit 44 may be collected into a flow line 45 for separate processing
to remove surfactant and fibers from the water and to permit
recycling of the water back to the papermaking machine 15.
[0095] FIG. 8 is a schematic diagram of another wet-press/fabric
crepe papermachine 35 having a conventional twin wire forming
section 37, a felt run 34, a shoe press section 36, a creping
fabric 38 and a Yankee dryer 40 suitable for making sheet used in
connection with the present invention. Forming section 37 includes
a pair of forming fabrics 42, 44 supported by a plurality of rolls
46, 48, 50, 52, 54, 56 and a forming roll 58. A headbox 60 provides
papermaking furnish in the form of a jet to a nip 62 between
forming roll 58 and roll 46 and the fabrics. Control of the jet
velocity relative to the forming fabrics is an important aspect of
controlling tensile ratio as will be appreciated by one of skill in
the art. The furnish forms a nascent web 64 which is dewatered on
the fabrics with the assistance of suction, for example, by way of
suction box 66.
[0096] The nascent web is advanced to a papermaking felt 68 which
is supported by a plurality of rolls 70, 72, 74, 75 and the felt is
in contact with a shoe press roll 76. The web is of low consistency
as it is transferred to the felt. Transfer may be assisted by
suction; for example roll 70 may be a suction roll if so desired or
a pickup or suction shoe as is known in the art. As the web reaches
the shoe press roll it may have a consistency of 10-25 percent,
preferably 20 to 25 percent or so as it enters nip 78 between shoe
press roll 76 and transfer roll 80. Transfer roll 80 may be a
heated roll if so desired. Instead of a shoe press roll, roll 76
could be a conventional suction pressure roll. If a shoe press is
employed it is desirable and preferred that roll 74 is a suction
roll effective to remove water from the felt prior to the felt
entering the shoe press nip since water from the furnish will be
pressed into the felt in the shoe press nip. In any case, using a
suction roll or STR at 74 is typically desirable to ensure the web
remains in contact with the felt during the direction change as one
of skill in the art will appreciate from the diagram.
[0097] Web 64 is wet-pressed on the felt in nip 78 with the
assistance of pressure shoe 82. The web is thus compactively
dewatered at 78, typically by increasing the consistency by 15 or
more points at this stage of the process. The configuration shown
at 78 is generally termed a shoe press; in connection with the
present invention cylinder 80 is operative as a transfer cylinder
which operates to convey web 64 at high speed, typically 1000
fpm-6000 fpm to the creping fabric.
[0098] Cylinder 80 has a smooth surface 84 which may be provided
with adhesive and/or release agents if needed. Web 64 is adhered to
transfer surface 84 of cylinder 80 which is rotating at a high
angular velocity as the web continues to advance in the
machine-direction indicated by arrows 86. On the cylinder, web 64
has a generally random apparent distribution of fiber.
[0099] Direction 86 is referred to as the machine-direction (MD) of
the web as well as that of papermachine 35; whereas the
cross-machine-direction (CD) is the direction in the plane of the
web perpendicular to the MD.
[0100] Web 64 enters nip 78 typically at consistencies of 10-25
percent or so and is dewatered and dried to consistencies of from
about 25 to about 70 percent by the time it is transferred to
creping fabric 38 as shown in the diagram.
[0101] Fabric 38 is supported on a plurality of rolls 88, 90, 92
and a press nip roll or solid pressure roll 94 such that there is
formed a fabric crepe nip 96 with transfer cylinder 80 as shown in
the diagram.
[0102] The creping fabric defines a creping nip over the distance
in which creping fabric 38 is adapted to contact roll 80; that is,
applies significant pressure to the web against the transfer
cylinder. To this end, backing (or creping) roll 90 may be provided
with a soft deformable surface which will increase the width of the
creping nip and increase the fabric creping angle between the
fabric and the sheet and the point of contact or a shoe press roll
could be used as roll 90 to increase effective contact with the web
in high impact fabric creping nip 96 where web 64 is transferred to
fabric 38 and advanced in the machine-direction. By using different
equipment at the creping nip, it is possible to adjust the fabric
creping angle or the takeaway angle from the creping nip. Thus, it
is possible to influence the nature and amount of redistribution of
fiber, as well as delamination/debonding which may occur at fabric
creping nip 96 by adjusting these nip parameters. In some
embodiments it may by desirable to restructure the z-direction
interfiber characteristics while in other cases it may be desired
to influence properties only in the plane of the web. The creping
nip parameters can influence the distribution of fiber in the web
in a variety of directions, including inducing changes in the
z-direction as well as the MD and CD. In any case, the transfer
from the transfer cylinder to the creping fabric is high impact in
that the fabric is traveling slower than the web and a significant
velocity change occurs. Typically, the web is creped anywhere from
10-60 percent and even higher during transfer from the transfer
cylinder to the fabric.
[0103] Creping nip 96 generally extends over a fabric creping nip
width of anywhere from about 1/8'' to about 2'', typically 1/2'' to
2''. For a creping fabric with 32 CD strands per inch, web 64 thus
will encounter anywhere from about 4 to 64 weft filaments in the
nip.
[0104] The nip pressure in nip 96, that is, the loading between
backing roll 90 and transfer roll 80 is suitably 20-100, preferably
40-70 pounds per linear inch (PLI).
[0105] After fabric creping, the web continues to advance along MD
86 where it is wet-pressed onto Yankee cylinder 100 in transfer nip
102. Transfer at nip 102 occurs at a web consistency of generally
from about 25 to about 70 percent. At these consistencies, it is
difficult to adhere the web to surface 104 of cylinder 100 firmly
enough to remove the web from the fabric thoroughly. Typically, a
poly(vinyl alcohol)/polyamide adhesive composition as noted above
is applied at 106 as needed.
[0106] If so desired, a suction box may be employed at 87 in order
to increase caliper. Typically, suction of from about 5 to about 30
inches of mercury is employed.
[0107] The web is dried on Yankee cylinder 100 which is a heated
cylinder and by high jet velocity impingement air in Yankee hood
108. As the cylinder rotates, web 64 is creped from the cylinder by
creping doctor (blade) 109 and wound on a take-up reel 110. Creping
of the paper from a Yankee dryer may be carried out using an
undulatory creping blade, such as that disclosed in U.S. Pat. No.
5,690,788, the disclosure of which is incorporated by reference.
Use of the undulatory crepe blade has been shown to impart several
advantages when used in production of tissue products. In general,
tissue products creped using an undulatory blade have higher
caliper (thickness), increased CD stretch, and a higher void volume
than do comparable tissue products produced using conventional
crepe blades. All of these changes effected by use of the
undulatory blade tend to correlate with improved softness
perception of the tissue products.
[0108] There is optionally provided a calender station 105 with
rolls 105(a), 105(b) to calender the sheet, if so desired.
[0109] When a wet-crepe process is employed, an impingement air
dryer, a through-air dryer, or a plurality of can dryers can be
used instead of a Yankee. Impingement air dryers are disclosed in
the following patents and applications, the disclosure of which is
incorporated herein by reference: [0110] U.S. Pat. No. 5,865,955 of
Ilvespaaet et al. [0111] U.S. Pat. No. 5,968,590 of Ahonen et al.
[0112] U.S. Pat. No. 6,001,421 of Ahonen et al. [0113] U.S. Pat.
No. 6,119,362 of Sundqvist et al. [0114] U.S. patent application
Ser. No. 09/733,172, entitled "Wet Crepe, Impingement-Air Dry
Process for Making Absorbent Sheet", now U.S. Pat. No.
6,432,267.
[0115] Throughdrying units are well known in the art and described
in U.S. Pat. No. 3,432,936 to Cole et al., the disclosure of which
is incorporated herein by reference. U.S. Pat. No. 5,851,353
discloses a can-drying system which is also well known in the
art.
[0116] Preferred aspects of processes including fabric-creping are
described in the following co-pending applications: U.S. patent
application Ser. No. 11/151,761, filed Jun. 14, 2005, entitled
"High Solids Fabric Crepe Process for Producing Absorbent Sheet
with In-Fabric Drying" (Attorney Docket 12633; GP-03-35); U.S.
patent application Ser. No. 11/402,609, filed Apr. 12, 2006,
entitled "Multi-Ply Paper Towel With Absorbent Core" (Attorney
Docket No. 12601; GP-04-11); U.S. patent application Ser. No.
11/451,112, filed Jun. 12, 2006, entitled "Fabric-Creped Sheet for
Dispensers" (Attorney Docket No. 20195; GP-06-12); U.S. Provisional
Patent Application Ser. No. 60/808,863, filed May 26, 2006,
entitled "Fabric Creped Absorbent Sheet with Variable Local Basis
Weight" (Attorney Docket No. 20179; GP-06-11); and U.S. application
Ser. No. 10/679,862, filed Oct. 6, 2003, entitled "Fabric Crepe
Process for Making Absorbent Sheet" (Attorney Docket. 12389;
GP-02-12) which applications, incorporated herein by reference,
disclose particular papermachine details as well as creping
techniques, equipment and properties. U.S. application Ser. No.
11/108,375, filed Apr. 18, 2005, entitled "Fabric Crepe/Draw
Process for Producing Absorbent Sheet" (Attorney Docket No.
12389P1; GP-02-12-1) also incorporated herein by reference,
provides still further processing and composition information; U.S.
application Ser. No. 11/108,458, filed Apr. 18, 2005, entitled
"Fabric Crepe and In Fabric Drying Process for Producing Absorbent
Sheet" (Attorney Docket 12611P1; GP-03-33-1) and U.S. application
Ser. No. 11/104,014, filed Apr. 12, 2005, entitled "Wet-Pressed
Tissue and Towel Products With Elevated CD Stretch and Low Tensile
Ratios Made With a High Solids Fabric Crepe Process" (Attorney
Docket 12636; GP-04-5) both of which are incorporated herein by
reference, provide some further variation as to selection of
components and processing techniques. Another copending
application, U.S. Ser. No. 11/451,111, filed Jun. 12, 2006,
entitled "Method of Making Fabric Creped Sheet for Dispensers"
(Attorney Docket No. 20079; GP-05-10), incorporated herein by
reference, provides information on suitable drying and other
manufacturing techniques.
[0117] The above process allows one to control the MD/CD tensile
ratio to a much greater extent than in CWP processes (as will be
appreciated from FIG. 3 which appears in U.S. patent application
Ser. No. 11/108,375) simply by varying the jet/wire velocity
delta.
[0118] Using base sheet prepared on papermachines of the class
shown in FIG. 8, single-ply paper towel was made and compared with
towel made from base sheet prepared without debonder pre-treatment
in accordance with the invention. Details appear in Table 2,
wherein it is seen that the products of the invention had higher
wet/dry CD tensile ratios and CD wet tensiles, as well as lower MD
dry tensiles. Moreover, debonder treated products had trained panel
softness values of up to 50 percent higher than equivalent products
made without debonder pre-treatment.
TABLE-US-00002 TABLE 2 FC Single Ply Towel Converted Product Data
Debonder Add-on AMRES/ Refiner B.W. Cal. MD CD Percent Panel
Debonder (#/T) CMC (hp) (#/rm) (mil/8sh) (g/3'') (g/3'') MD/CD CD
Wet w/d WAR(s) Softness TQ-1152 20 19/5.5 35 22.88 71.63 1945 1421
1.37 607 43 12.2 6.60 TQ-1152 20 19/5.5 42 22.10 71.35 2244 1496
1.50 626 42 14.4 6.10 Cartaflex 10 19/5.5 23 23.02 72.13 2214 1469
1.51 532 36 11.8 6.37 Cartaflex 8 19/5.5 23 22.98 66.78 2809 1973
1.42 723 37 14.8 4.74 Control 22.65 66.08 2979 1876 1.59 406 22 7.1
4.39
[0119] Unexpectedly, the high levels of debonder employed did not
interfere with adhesion to the transfer cylinder or the Yankee
dryer or cause other processing difficulties. The invention
accordingly enables wet/dry CD tensile ratios increase of up to
nearly 100 percent in commercial wet-press towel operations.
[0120] It will be appreciated from the foregoing that there is
provided in a first aspect of the invention a method of making
absorbent cellulosic sheet with increased wet/dry CD tensile ratio
comprising: a) preparing an aqueous furnish consisting essentially
of cellulosic papermaking fibers in aqueous suspension having a
consistency of greater than 2 percent, wherein the papermaking
fiber includes Kraft softwood fiber in an amount of at least 25
percent by weight of fiber; b) treating the aqueous furnish at
greater than 2 percent consistency with from about 5 lbs of
debonder per ton of papermaking fiber to about 30 lbs of debonder
per ton of papermaking fiber; c) typically, subsequent to the step
of treating the aqueous furnish at greater than 2 percent
consistency with debonder, adding a permanent wet strength resin to
the aqueous furnish in an amount of from about 5 lbs of permanent
wet strength per ton of papermaking fiber to about 50 lbs of
permanent wet strength resin per ton of papermaking fiber; d)
diluting the aqueous furnish to a consistency of less than 2
percent; e) depositing the diluted aqueous furnish onto a
foraminous support traveling in a machine direction at a wire speed
by way of a jet of the diluted aqueous furnish having a jet
velocity in the machine direction; f) dewatering the furnish on the
foraminous support to form a nascent web; g) wet-pressing the
nascent web onto a rotating cylinder; and h) drying the web to
produce the cellulosic sheet. The steps of dewatering, wet-pressing
and drying the web as well as the jet to wire velocity delta are
controlled and the furnish, debonder, dry strength resin and
permanent wet strength resin are selected and utilized in amounts
such that the absorbent cellulosic sheet has a wet/dry CD tensile
ratio of greater than 30 percent. CD wet/dry tensile ratios are
typically between about 35 percent and 60 percent; greater than 40
percent or 45 percent in suitable embodiments when CMC dry strength
resin is used. MD/CD dry tensile ratios of less than 1.5 or less
than about 1 are achieved in connection with CWP processes. In FC
processes, MD/CD dry tensile ratios of less than 0.75 or less than
0.5 are readily achieved.
[0121] In many preferred cases, the furnish is treated with from
about 10 lbs of debonder per ton of papermaking fiber to about 20
lbs of debonder per ton of papermaking fiber and the aqueous
furnish is treated with debonder at a consistency of greater than 3
percent or 4 percent; typically between about 3 percent and up to
about 8 to 10 percent consistency.
[0122] Dry strength resin is optionally added in an amount of from
about 2.5 lbs of dry strength resin per ton of papermaking filler
to about 10 lbs of dry strength resin per ton of papermaking fiber.
One preferred dry strength resin is carboxymethyl cellulose.
[0123] The permanent wet strength resin is added to the furnish in
an amount of from about 5 lbs per ton of papermaking fiber to about
40 lbs per ton of papermaking fiber; perhaps more preferably, the
permanent wet strength resin is added to the furnish in an amount
of from about 10 lbs per ton of papermaking fiber to about 30 lbs
per ton of papermaking fiber.
[0124] Some processes of the invention include refining at least a
portion of the papermaking fiber as well as the step of blending
the debonder-treated aqueous furnish with another aqueous furnish
containing papermaking fiber.
[0125] Various processes of the invention include one or more of
the following features: (a) at least 50 percent by weight of the
papermaking fiber in the sheet is pretreated with debonder; (b) at
least 75 percent by weight of the papermaking fiber in the sheet is
pretreated with debonder; (c) at least 90 percent by weight of the
papermaking fiber in the sheet is pretreated with debonder; (d) the
papermaking furnish comprises recycle fiber; (e) the recycle fiber
comprises predominantly low yield recycle fiber as opposed to
groundwood; (f) substantially all Kraft softwood fiber in the sheet
is treated with debonder; (g) the rotating cylinder is a rotating
heated cylinder whereupon the web is dried and the process further
includes the step of creping the web form the heated cylinder with
a creping doctor at reel crepe of from about 2 percent to about 25
percent; (h) the dried web is creped from the heated cylinder with
a creping doctor at a reel crepe of from about 5 percent to about
20 percent; (i) the softwood pulp is treated with debonder for at
least 10 minutes at a consistency of greater than 2 percent; (j)
the softwood pulp is treated with debonder for at least 20 minutes
at a consistency of greater than 2 percent; and (k) the softwood
pulp is treated with debonder for at least 30 minutes at a
consistency of greater than 2 percent.
[0126] In still another aspect of the invention, there is provided
a method of making absorbent cellulosic sheet with increased
wet/dry CD tensile ratio comprising: a) preparing an aqueous
furnish consisting essentially of cellulosic papermaking fibers in
aqueous suspension having a consistency of greater than 2 percent;
b) treating the aqueous furnish at greater than 2 percent
consistency, preferably greater than 5 percent consistency with
from about 5 lbs of debonder per ton of papermaking fiber to about
30 lbs of debonder per ton of papermaking fiber; c) subsequent to
the step of treating the aqueous furnish at greater than 2 percent
consistency with debonder, adding a permanent wet strength resin to
the aqueous furnish in an amount of from about 5 lbs of permanent
wet strength per ton of papermaking fiber to about 50 lbs of
permanent wet strength resin per ton of papermaking fiber; d)
diluting the aqueous furnish to a consistency less than the
consistency at which furnish was treated with debonder, preferably
less than 4 or 3 percent and most preferably less than 2 or 1
percent; e) depositing the diluted aqueous furnish onto a
foraminous support traveling in a machine direction at a wire speed
by way of a jet of the diluted aqueous furnish having a jet
velocity in the machine direction; f) compactively dewatering the
furnish to form a nascent web having an apparently random
distribution of papermaking fiber; g) applying the dewatered web
having the apparently random fiber distribution to a translating
transfer surface moving at first speed; h) belt-creping the web
from the transfer surface at a consistency of from about 30 percent
to about 60 percent utilizing a patterned creping belt, the creping
step occurring under pressure in a belt creping nip defined between
the transfer surface and the creping belt wherein the belt is
traveling at a second speed slower than the speed of said transfer
surface, the belt pattern, nip parameters, velocity delta and web
consistency being selected such that the web is creped from the
transfer surface and redistributed on the creping belt to form a
web with a reticulum having a plurality of interconnected regions
of different local basis weights including at least (I) a plurality
of fiber-enriched pileated regions of high local basis weight, as
well as (II) a plurality of regions of compressed papermaking
fibers, the compressed regions having relatively low local basis
weight; and i) drying the web to produce the cellulosic sheet;
wherein the steps of dewatering and applying the web to the
transfer surface, belt creping, wet-pressing, and drying the web as
well as the jet to wire velocity delta are controlled and the
furnish, debonder, and permanent wet strength resin are selected
and utilized in amounts such that the absorbent cellulosic sheet
has a wet/dry CD tensile ratio of greater than 30 percent.
[0127] Typically, the web is creped from the transfer surface at a
Belt Crepe of between 2 percent and 80 percent; for towel used in
electronic dispensers the web is creped from the transfer surface
at a Belt Crepe of between 3 percent and 8 percent. In other cases,
the web is creped from the transfer surface at a Belt Crepe of at
least 10 percent or more such as wherein the web is creped from the
transfer surface at a Belt Crepe of at least 20 percent, 30
percent, or the web is creped from the transfer surface at a Belt
Crepe of at least 50 percent.
[0128] In still other aspects of the invention, mixtures of Kraft
hardwood and softwood fibers are employed, such as wherein the
fiber in the aqueous furnish is at least 75 percent by weight Kraft
papermaking fiber; or wherein the fiber in the aqueous furnish is
at least 90 percent by weight Kraft papermaking fiber; and/or
wherein the papermaking fiber in the aqueous furnish is at least
about 40 percent or 50 percent by weight Kraft softwood fiber. In
still other embodiments, the papermaking fiber in the aqueous
furnish is at least about 60 or 70 percent by weight Kraft softwood
fiber.
[0129] Generally, Kraft softwood fiber employed has a length
weighted average fiber length of greater than 1 mm; whereas
typically, Kraft softwood fiber has a length weighted average fiber
length of greater than 1.5 mm. In most cases, the Kraft softwood
fiber has a length weighted average fiber length of between about
1.5 mm and about 3 mm.
[0130] While the invention has been described in connection with
several examples, modifications to those examples within the spirit
and scope of the invention will be readily apparent to those of
skill in the art. In view of the foregoing discussion, relevant
knowledge in the art and references including co-pending
applications discussed above in connection with the Background and
Detailed Description, the disclosures of which are all incorporated
herein by reference, further description is deemed unnecessary.
* * * * *